Punch and die assembly



July 6, 1965 1-. E. HOSKINS PUNCH AND DIE ASSEMBLY 5 Sheets-Sheet 2Filed July 28, 196i 4 INVENTOR.

Thomas E. Hosk/ns z/5,

HIS ATTORNE Y5 Filed July' 28. 1961 r. a'i-loskm's PUNCH AND' DIEASSEMBLY 5 Sheets-Sheet 5 HIS ATTORNEYS 1'. E. aosxms PUNCH AND DIEASSEMBLY July 6, 1965 5 Sheets-Sheet 4 7 w F F Filed July 28. 1961 glg o8 m 4 O 6 3 4 I 4 a h 2 a m %u %Z w a m m INVENTOR. Thomas E. Haskinsk/$74446 97M HIS ATTORNEYSVYY July 6, 1965 1'. E. HOSKINS 3,192,791

PUNCH AND DIE ASSEMBLY I Filed July as. 1961 5 Sheets Sheet 5 Fig.8

I04 48 I00 48 Q 94 102 42o +44 g 2% 5e 26 56 68/52 0 o 52 as p/ /A/ //iI \J' Ill 5 INVENTOR. Thomas E Ha'skins United States Patent O 3,192,761PUNCH AND DIE ASSEMBLY Thomas E. Hoslrins, Moon Township, AlleghenyCounty, Pa., assignor, by mesne assignments, to Raceways, Inc., NewBrunswick, NJ., a corporation of Delaware Filed July 28, 1961, Ser. No.127,737 10 Claims. (Cl. 72-464) This invention relates to a punch anddie assembly. More particularly, it relates to a novel segmented die andpunch assembly used to pierce and flare holes in underfloor duct workand assemble outlet cups thereto.

In underfloor electrical raceway systems it is frequently necessary toutilize underfloor ducts having outlets spaced periodically along itslength. For example, it is quite common to utilize underfloor ductshaving an outlet every two feet. For this purpose a ten foot duct wouldhave five outlets. The manufacture of ducts having these spaced outletsis now a time consuming and expensive operation. The operation includesmaking a hole in the duct work, flaring the edges around the hole andfastening an outlet cap to the duct for each outlet opening. At presentthe hole is made by trepanning the duct. The trepanned duct is placed ona die and the edges are flared outwardly in two operations, part of thehole being flared in each operation. The outlet cup is then positionedon the flared edges and is fastened to the flared edges. This fasteningoperation also requires two steps. Thus, to fasten one outlet cup to aduct five operative steps are required.

This invention provides a novel punch and die assembly which will piercethe duct, flare the edges of the pierced hole and fasten the outlet cupto the duct in two operative steps. The duct is pierced and flared inone step and the outlet cup fastened to the pierced hole with oneadditional step. The entire operation can be accomplished in 20% of thetime now required to fasten outlet cups to underfloor ducts by themethods currently used as described above.

Briefly stated, the invention consists of a die having laterally movablesegments which support a solid die ring. The segments and the die ringare constructed with mating sides designed so that as the segments areextended laterally they force the ring member horizontally upward. Thepunch is designed to engage an actuating cam which in turn expands thesegments causing the solid die ring to move upwardly. In one operation,the punch pierces the duct and the ring member flares the edges aroundthe pierced hole upwardly. In the second operation, the ring membercrimps the edges of an outlet cup to the flared edges of the holethereby fastening the outlet cup to the duct.

In the accompanying drawings, I have illustrated presently preferredembodiments of my invention, wherein:

FIGURE 1 is a vertical section through a punch and die of this inventionadapted and arranged to pierce and flare a duct;

FIGURE 2 is a vertical section similar to FIGURE 1 showing the punch anddie in operative arrangement at the bottom of a stroke;

FIGURE 3 is a section on lines III-III of FIGURE 1;

FIGURE 4 is a horizontal section taken on lines IV-IV of FIGURE 2;

FIGURE 5 is a plan view of the die of this invention;

FIGURE 6 is a section on lines VIVI of FIGURE 5;

FIGURE 7 is a vertical section similar to FIGURE 1 showing the punch anddie of this invention arranged to fasten an outlet cup to the piercedand flared duct;

FIGURE 8 is a vertical section similar to that shown in FIGURE 2 showingthe punch and die of this invention in operative relationship at thebottom of a stroke;

' bottoms of the shanks.

ice

FIGURE 9 is an enlarged view of the junction formed between the outletcup and the underfloor duct by the punch and die of this invention; and

FIGURE 10 is a vertical section showing the completed assembly of theoutlet cup to the underfloor duct.

Referring to the drawings, a die, designated generally 16, is shownpositioned in an underfloor duct 12. The die has a main die block 14 towhich a base plate 16 is attached, forming a hollow central section 18in the die block. An annular ring 26 formed from a plurality of segments22 rests on the base plate 16. The segments are formed with a flat uppersurface 24 and sloping sides26 and 28. A groove 30 formed around theperiphery of the segments holds a coil spring 32. The spring 32 biasesthe segments inwardly and holds them in a circular annularconfiguration. Their inward movement is restrained by a projection 34formed at the central portion of the base member 16.

A solid annular die ring 36 rests on the outwardly sloping sides of thesegments 22, and abuts the surface of the hollow central section 18 ofthe die block 14. The bottom surface of ring 36 which rests on segments22 is sloped to mate with the sloping surface 28 of the segments. Thus,as the segments are expanded outwardly, the solid die ring 36 will beraised.

Referring now specifically to FIGURES 1 and 2 which show the specificembodiment of the die of this invention adapted to pierce and flare theduct, the upper portion of the die ring 36 has an internal diameterequal to the diameter of the hole to be pierced in the duct. The upperportion thus is of a much reduced diameter from the lower portion of theannular ring. The upper surface of the ring 36 has a short, fiat sectionand an outwardly sloping section 38 and 40 respectively.

A central actuating cam 42 rests on the inwardly sloping surface 26 ofthe segmented ring and is held in position by a bolt 44 threaded intothe base plate 16. The bottom surface of the central member 42 has asloping surface which mates with the sloping surface 26 of the segments.As the actuating cam 42 is pushed downwardly, it forces the segmentsoutwardly which in turn forces the die ring 36 upwardly. Again referringto the embodiments shown in FIGURES 1 and 2, the central section in thisembodiment has a circular rib 46 on the upper surface thereof. The dieblock 14 is formed with two vertically extending holes therethroughadjacent the hollow central section 18. T-shaped members 48 have theirshanks inserted into the holes and are surrounded by coil spring 50which are held to the T-shaped members by buttonhead screws 52 which arefastened into the A circular groove 54 is cut out of the outer edge ofthe die ring 36 and the inner edge of the die block 14. The groove formsan outwardly extending ledge 55 in the ring 36 over which the head ofthe T-shaped member 4-8 extends into the groove. Thus, as the die ring36 is forced upwardly by the expanding segmented ring 20, it engages thehead of the T-shaped member forcing it upwardly and compressing the coilspring 50. When the actuating force is withdrawn allowing the segmentsto retract, the spring 32 pulls the segments back into their originalring-like position and the springs 50 force the annular die ring 36 backinto its original position.

The die block 14 also has two horizontally extending holes 56therethrough. As best seen in FIGURE 6, these holes house side gaugeassembly 58. The assembly consists of a set screw 60 and a gauge pin 62separated by a coil spring 68. The die block is formed with narrowprojections 64 and 65 on each side thereof. The projection 64 acts as abearing surface. When the die is inserted in the duct, the gauge pin 62forces the projection 64 into contact with the inner surface of the 1?duct. Thus, as the die it" is inserted in the duct 12, it is positionedat the desired longitudinal position in the duct by the side gauge 58.The tapered front end 66 of the pin 62 extends beyond projection 65, butif the pin 62 is worn or the spring 63 is operating improperly, theprojection will act as an emergency bearing surface.

The die block is formed with a longitudinal hole extending from one endinto the hollow central section which houses a tube 69 which in turn isconnected to a source of air so that air may be forced through thehollow central section.

The punch of this invention has inner and outer members movable withrespect of each other. In FIGURES 1 and 2 the punch used in the piercingand flaring operation is specifically shown. It consists of a supportmember 70 to which an inner punch member 72 is fastened by bolt 74. Theface of member '72 has a circular groove around the periphery to conformwith the rib 46 on the actuating cam of the die. It is annular and has adiameter equal to the diameter of the hole to be pierced in the duct.The edges are at right angles and are cutting edges. An annular member76 is positioned around the member '72 and is fastened to member 79 bymeans of bolts 78 which extend through member 70 and are threaded intothe annular member 76. Coil springs St surround bolts 78 and abut thehead 70 and annular member 76. Stops 82 are fastened by means of bolts84- to the head '79. Thus, member 76 may be moved with respect to member72 until it abuts members 82 as shown in FIGURE 2. After the forcecausing the movement is eliminated, springs 80 return the members '72and 76 to their original position as shown in FIGURE 1. The bottomsurface of the member 76 is cut at an angle at the point where it abutsthe member 72 as shown at 86.

In operation, the member 72 hits the duct 12 piercing the hole thereinand hitting the member 42 forcing it down and expanding the segments 22forcing the annular ring member 36 upwardly which flares the edge of thepierced hole as shown in FIGURE 2. After the operation is completed andthe operating force removed, the springs 32, 50 and 80 return themembers to the original position shown in FIGURE 1. The stops 82 preventexcessive movement of the member 72 with respect of the member 76. Theperipheral rib 46 bends the cutout section 89 of the duct 12 so that itdoes not bind in the opening and will be elevated when the position isreturned to normal. As the actuating force is removed, an air stream isautomatically turned on, forcing air through a tube 69. The blank 89 iselevated above the die block by the air stream and is blown away fromthe assembly by a second horizontal air stream (not shown).

Referring now to FIGURES 7 and 8 showing the specific embodiment of thepunch and die of this invention adapted to fasten an outlet cup to thepierced and flared duct, the die ring 36 (FIGURE 1) is replaced by amodified die ring 36a. The ring 36a cooperates with segments 22 in thesame manner as does the ring 36. The upper portion of the die ring 36ais of a different configuration than that of ring 36. The inner diameterof ring 36a is less than the inner diameter of ring 36. The outer edgeof ring 36:: is formed with a radius 91 and a chamfer 93.

The actuating cam 42 (FIGURE 1) is replaced by an opertaing cam 42a. Thecam 42a operates on segments 22 in the same manner as cam 4-2. However,cam 42:: does not have a rib on the upper surface thereof. The uppersurface of the cam 42a is flat.

The punch used with the die for assembling an outlet cup to the duct hasa head 7% to which is bolted a T- shaped spacing member hi). Anoperating head 92 is fastened to the base of the T-shaped member 90 bymeans of bolt 94. An outer member 96 encircles the T-shaped member 9!and is movable with respect thereto. A coil spring 98 encircles theshank of theT-shaped member 9i) and abuts the head of member 90 andmember 95. When the punch has no force applied to it, the coil spring 98forces the member 96 against head 92. When force is applied to the head"it? of the punch, the spring will be compressed and the members 9% and92 move with respect of the member 96. The extent of the motion islimited by the head of T-shaped member 90 which will stop the movementby contact with the member 96. The diameter of the member is justslightly less than the internal diameter of the outlet cup to befastened to the duct.

The outlet cup to fastened to the duct is made with a bifurcated endwhich is pinched on the flared duct. As shown in FIGURE 7 the outlet cuphastwo legs 10% and 1&2 which rest on either side of the flared duct.The bifurcated structure provides a shoulder 194 at the junction of thetwo legs Silt? and 102. The lower end of member 96 of the punch isformed with an offset at its outer perimeter which provides a shoulder106. As the punch is inserted into the outlet cup, the shoulder 106mates with shoulder 194 holding the outlet cup firmly in the place asthe member 92 continues hitting the operating cam 42a forcing thesegments outwardly and raising the die ring 36a. As the die ring 36a israised, the radius 91 on the edge of the die ring catches leg 152 of theoutlet cup bending it outwardlycrimping it firmly against the internalsurface of the flared hole in the duct. The chamfer 93 on the edge ofthe die ring provides clearance between the ring a and the leg 16.2 sothat the crimping will be completed. At this point the punch and die setis in the position shown in FIGURE 8. The springs 98, 59 and 32 returnthe parts to their original position when the actuating force isremoved. The finished duct with the outlet cup firmly attached theretois shown in FIG- URE 10.

From the foregoing it is apparent that the improved punch and die ofthis invention makes possible the assembly of an outlet cup to the floorducts in two quick operations. The duct is pierced and flared outwardlyin one stroke of the punch and the outlet cup is assembled to thepierced and flared hole in one action of the punch. This substantiallyreduces the time required to assemble an outlet to the duct work. Theart now has a separate piercing or trepanning operation. Two separateoperations of a punch and die are required to flare the duct and twooperations of the punch are required to attach the outlet cup thereto.

While I have described the present preferred embodiments of myinvention, it should be understood that it may otherwise be embodiedwithin the scope of the following claims.

I claim:

1. A punch and die assembly comprising a die member having a pluralityof laterally movable, spring mounted segments forming an annularsegmented ring, the sides of the segments sloping outwardly forminginner and outer bearing surfaces, an actuating cam resting on the innerbearing surface of the segments and movable downwardly to expand thesegmented ring, and a solid annular die ring resting on the outerbearing surface of the segments, the die ring being raised by lateralmovement of the segments, and a punch having inner and outer membersmovable with respect to each other, the inner member being adapted tocontact the actuating cam and force it downwardly.

2. A punch and die assembly comprising a die member having a die blockhaving a hollow central cavity, a base plate attached to the die block,a plurality of laterally movable segments forming an annular segmentedring positioned on the base plate in the hollow cavity of the die block,each segment having a groove in its side providrng a peripheral groovearound the segmented ring, a coil spring mounted in the peripheralgroove inwardly biasing the segmented ring, an actuating cam resting onthe segments and movable downwardly -to expand the segments, an annulardie ring resting on the segments and having a groove cut in its outersurface, the die ring being raised by lateral movement of the segment-s,a T- shaped member positioned in the die block adjacent the hollowcentral cavity, the head of the T-shaped member extending into thecavity and engaging the groove in the die ring, a coil spring mounted onthe shank of the T- shaped member downwardly biasing the T-shapedmember, and a Punch adapted to contact the actuating cam and force itdownwardly.

3. A punch and die assembly for piercing and flaring underfloor ductscomprising a die member dimensioned to fit inside an underfloor duct,said die member having a die block having a hollow central cavity, abase plate attached to the die block, a plurality of laterally movablesegments forming an annular segmented ring positioned on the base platein the hollow cavity of the die block, the segmented ring being biasedinwardly, an actuating cam resting on the segments and movably mountedto the base plate, the cam being movable downwardly to laterally expandthe segmented ring, an annular die ring resting on the segments, theinner diameter of the upper portion of the annular die ring being equalto the diameter of the hole to be pieced and the outer edge of the upperface of the ring sloping downwardly and outwardly, the die ring beingraised by lateral movement of the segments, and a punch having outer andinner members movable with respect of each other, the outer memberhaving an internal diameter equal to the inner diameter of the die ringand having its inner edge out off, and the inner member fitting insidethe outer member and being adapted to pierce the duct contact theactuating cam and force it downwardly, the downward movement of the camexpanding the segments forcing the die block upward, the outer edge ofthe die block and the inner edge of the outer punch member cooperatingto flare the edge of the pierced hole.

4. A punch and die assembly for piercing and flaring underfloor ductscomprising a die member dimensioned to fit inside an underfloor duct,said die member having a die block having a hollow central cavity, abase plate attached to the die block, a narrow longitudinal projectionextending from at least one side of the die block, at least one sidegauge extending transversely through the die block, the side gaugehaving a spring mounted gauge pin extending from the side opposite theside from which the longitudinal projection extends, the gauge pinseating the projection against the inner surface of the duct, aplurality of laterally movable segments forming an annular segmentedring positioned on the base plate in the hollow cavity of the die block,an actuating cam resting on the segments and movably mounted to the baseplate, the cam being movable downwardly to expand the segmented ring, anannular die ring resting on the segments, said die ring being raised bylateral movement of the segments, and a punch adapted to pierce the ductand force the cam downwardly whereby the die ring is elevated flaringthe edges of pierced hole in the duct.

5. A punch and die assembly for piercing and flaring underfloor ductscomprising a die member dimensioned to fit inside an underfloor duct,said die member having a die block having a hollow central cavity, abase plate attached to the die block, a plurality of laterally movablesegments forming an annular segmented ring positioned on the base platein the hollow cavity of the die block, the segmented ring being biasedinwardly and the sides of the segments sloping outwardly forming innerand outer bearing surfaces, an actuating cam resting on the innerbearing surface of the segments and movably mounted to the base plate,the cam being movable downwardly to laterally expand the segmented ring,an annular die ring resting on the outer bearing surface of thesegments, the inner diameter of the upper portion of the annular diering being equal to the diameter of the hole to be pierced and the outeredge of the upper face of the ring sloping downwardly and outwardly, thedie ring being raised by lateral movement of the segments, and a punchhaving outer and inner members movable pierce the duct contact theactuating cam and force it I downwardly, the downward movement of thecam expanding the segments forcing the die block upward, the outer edgeof the die block and the inner edge of the outer punch membercooperating to flare the edge of the pierced hole.

6. A punch and die assembly for piercing and flaring underfloor ductscomprising a die member having a die block having a hollow centralcavity, a base plate attached to the die block, a plurality of laterallymovable segments forming an annular segmented ring positioned on thebase plate in the hollow cavity of the die block, the segmented ringbeing biased inwardly, an actuating cam resting on the segments andmovably mounted to the base plate, the cam being movable downwardly tolaterally expand the segmented ring and having a rib around theperiphery of its upper surface, an annular die ring resting on thesegments, the inner diameter of the upper portion of the annular diering being equal to the diameter of the hole to be pierced and the outeredge of the upper face of the ring sloping downwardly and outwardly, thedie ring being raised by lateral movement of the segments, and a punchhaving outer and inner members movable with respect of each other, theouter member having an internal diameter equal to the inner diameter ofthe die ring and having its inner edge cut oif, and the inner memberfitting inside the outer member and having a groove around the peripheryof its face and being adapted to pierce the duct contact the actuatingcam and force it downwardly, the downward movement of the cam expandingthe segments forcing the die block upward, the outer edge of the dieblock and the inner edge of the outer punch member cooperating to flarethe edge of the pierced hole, and the rib on the actuating cam and thegroove in the inner punch member cooperating to bend the blank.

7. The punch and die assembly defined in claim 6 in which the die has anair tube extending through the die block and into the central cavity,and the air tube is connected to a source of air whereby the blank maybe forced out of central cavity by an air stream.

8. A punch and die assembly for assembling an outlet cup to a flarededge of a hole in an underfloor duct, the outlet cup having .abifurcated end which fits around the flared edge, the assemblycomprising a die member having a plurality of laterally movable segmentsforming an annular segmented ring, the sides of the segments slopingoutwardly forming inner and outer bearing surfaces, an actuating camresting on the inner bearing surface of the segments and movabledownwardly to laterally expand the segmented ring, a solid annular diering resting on the outer bearing surface of the segments, the outeredge of the die ring being cut-off to form an inner radius and an outerchamfer, the die ring being raised by lateral movement of the segments,and a punch having inner and outer members movable with respect to eachother, the outer member being adapted to grip the outlet cup and hold itin position and the inner member being adapted to force the actuatingcam downwardly expanding the segmented ring and forcing the die ringupwardly, the inner radius of the die ring crimp ing the bifurcated endof the outlet cup to the flared edge of the duct.

9. A punch and die assembly for fastening an outlet cup to a flared edgeof a hole in an underfloor duct, the outlet cup having a bifurcated endwhich fits around the flared edge and provides an internal shoulder onthe outlet cup, the assembly comprising a die member having a die blockhaving a hollow central cavity, a base plate attached to the die block,a plurality of laterally movable segments forming an annular segmentedring positioned on the base plate in the hollow cavity of the die block,the sides of the segments sloping outwardly forming inner and outerbearing surfaces and the segmented ring being inwardly biased, anactuating cam resting on the inner bearing surface of the segments andbeing movably mounted to the base plate, the cam being movabledownwardly to laterally expand the segmented ring, a solid annular diering resting on the outer bearing surface of the segments, the outeredge of the die ring .being cut-off to form an inner radius and an outerchamfer, the die ring being raised by lateral movement of the segments,a punch having inner and outer members movable with respect to eachother, the outer member having an offset at its outer perimeterproviding a shoulder adapted to grip the shoulderon the outlet cup andhold the cup in position and the inner member being adapted to contactthe actuating cam forcing it downwardly and forcing the die ringupwardly whereby the inner radius of the die ring crimps the bifurcatedend of the outlet cup to the flared edge of the duct.

10. A punch and die assembly for fastening an outlet cup to a flarededge of a hole in an underfloor duct, the outlet cup having a bifurcatedend which fits around the flared edge, the assembly comprising a diemember dimensioned to fit inside an underfloor duct, said die memberhaving a die block having a hollow central cavity, a base plate attachedto the die block, a narrow longitudinal projection extending from atleast one side of the die block, at least one side gauge extendingtransversely through the die block, the side gauge having a springmounted gauge pin extending from the side opposite the side from whichthe longitudinal projection extends, the gauge pin seating theprojection against the inner surface of the duct, a plurality oflaterally movable segments forming an annular segmented ring positionedon the base plate in the hollow cavity of the die block, the sides ofthe segments sloping outwardly forming inner and outer bearing surfaces,an actuating carn resting on the inner bearing surface of the segmentsand movable downwardly to laterally expand the segmented ring, a solidannular die ring resting on the outer bearing surface of the segments,the outer edge of the die ring being cutofi to form an inner radius andan outer chamfer, the die ring being raised by lateral movement of thesegments, and a punch having inner and outer members movable Withrespect to each other, the outer member being adapted to grip the outletcup and hold it in position and the inner member being adapted to forcethe actuating cam downwardly expanding the segmented ring and forcingthe die ring upwardly, the inner radius of the die ring crimping thebifurcated end of the outlet cup to the flared edge of the duct.

References (Iitezl by the Examiner UNITED STATES PATENTS 1,857,628 5/32Eisenlohr 1l348 CHARLES \V. LANHAM, Primary Examiner.

NEDVJIN BERGER, Examiner.

1. A PUNCH AND DIE ASSEMBLY COMPRISING A DIE MEMBER HAVING A PLURALITYOF LATERALLY MOVABLE, SPRING MOUNTED SEGMENT FORMING AN ANNULARSEGMENTED RING, THE SIDES OF THE SEGMENTS SLOPING OUTWARDLY FORMINGINNER AND OUTER BEARING SURFACES, AN ACTUATING CAM RESTING ON THE INNERBEARING SURFACE OF THE SEGMENTS AND MOVABLE DOWNWARDLY TO EXPAND THESEGMENTED RING, AND A SOLID ANNULAR DIE RING RESTING ION THE OUTERBEARING SURFACE OF THE SEGMENTS, THE DIE RING BEING RAISED BY LATERALMOVEMENT OF THE SEGMENTS, AND A PUNCH HAVING INNER AND OUTER MEMBERMOVABLE WITH RESPECT TO EACH OTHER, THE INNER MEMBER BEING ADAPTED TOCONTACT THE ACTUATING CAM AND FORCR IT DOWNWARDLY.